LIGHTWEIGHT BLOWER
Blowing devices (100) have many uses; for example, they can be used to dry, cool, clean, or move objects. These functions are often performed by human beings with limited carrying capacity and endurance; therefore, a lightweight blower (100) is desired to perform the above tasks more easily. In accordance with the example uses, the present disclosure includes a lightweight blower (100) having an upper scroll (11), a lower scroll (10), and a joint (15) where the two scrolls (10, 11) are welded together to form a strong, lightweight joint (15).
Latest HUSQVARNA CONSUMER OUTDOOR PRODUCTS N.A., INC. Patents:
The present application claims the benefit of U.S. Provisional Patent Application 61/012,865, filed on Dec. 11, 2007. Said application is incorporated herein by reference in its entirety.
FIELDThe present disclosure relates generally to leaf blowers, and more particularly to the assembly of such blowers.
BACKGROUNDHandheld power tools, such as leaf blowers, blower/vacs, line trimmers, chain saws, edgers, and the like are used more and more for different kinds of work. For example, leaf blowers are an effective and time saving tool for cleaning large areas such as parking places, pavements, lawns and footpaths. Leaf blowers also make it possible to clean large areas more thoroughly, in an easy way. During cleaning of an area with conventional equipment, obstructions such as cars parked in parking spaces can make it necessary to leave parts of the area uncleaned. However, if the same area is cleaned with a leaf blower it is possible to blow away the rubbish underneath the parked cars, which will increase efficiency, save time and improve results. Some leaf blowers can also include a vacuum feature in which the direction of air flow is reversed and leaves and other objects are drawn by the leaf blower into a receiving bag.
Even though the leaf blower is an effective tool that helps the operator to clean large areas, many leaf blowers available on the market today are large and heavy with a center of gravity located at a long distance from the operator. Blowers also generate substantial vibration and noise which makes their use very tiring and/or uncomfortable for the operator and for other persons located close to the tool.
In addition to problems with noise and vibration, there may be air leakage between two scrolls of a blower allowing for air to escape causing a decrease in efficiency of the blower. The attachment points are often secured together via screws, which, in addition to causing air leakage, increases blower weight and manufacturing costs. Also, because the blower is secured only at a series of points, locations along the blower joint without screws suffer from decreased structural rigidity because there may be nothing to secure the joint at locations without attachment points. This decreased structural rigidity is a detriment because if the blower is dropped, it is more likely to break apart and cause injury to the user or others nearby. Thus, there has been a need for an improved blower seal resulting in better performance, decreased cost, less vibration, and improved safety. The present disclosure meets this need.
Embodiments of the present application will now be described, by way of example only, with reference to the accompanying drawings, wherein:
Example embodiments that incorporate one or more aspects of the present disclosure are described and illustrated in the drawings. These illustrated examples are not intended to be a limitation on the present disclosure. For example, one or more aspects of the present disclosure can be utilized in other embodiments and even other types of devices. Moreover, certain terminology is used herein for convenience only and is not to be taken as a limitation on the present disclosure. Still further, in the drawings, the same reference numerals are employed for designating like elements.
The leaf blower 100 also includes a handle 13 for carrying and pointing/directing the blower 100. The handle 13 is intended to be a representative example, and can include various other sizes, geometries, and/or features. In one example, the handle 13 may be formed separately and attached to the housing 14 or various other components of the blower 100. For example, as shown, the handle 13 can be coupled to a portion of the engine housing 14. The handle 13 can be coupled to the engine housing 14 in various ways, including with fasteners (e.g., screws, bolts, etc.), snap/click fastening arrangements, press fit, interference fit, adhesives, welding, and/or various other removable or non-removable fastening arrangements, and/or combinations thereof. In another embodiment, the handle 13 may be fixed to the scroll housing. Alternatively, the handle 13 may be formed as an integral component of housing 14. Additionally, the handle 13 may have a different shape or configuration, such as being fixed at two or more points rather than the cantilevered configuration with one attached end and one free end as illustrated.
In addition or alternatively, an isolator may be utilized between the handle 13 and the remainder of the blower to help control the transmission of vibration from the power drive unit and/or impeller to the user. In one example, the vibration isolator may be placed between the handle 13 and the engine housing 14. For example, the vibration isolator can include a sleeve (e.g., a “rubber grommet” style sleeve or the like) that is installed on the handle 13, and then inserted snugly into the engine housing 14 housing during installation of the handle 13. Thus, the vibration isolator can inhibit or even prevent vibrations from being transmitted to the user through the handle 13.
In addition, the fastening of the handle arrangement 13 can be performed by the manufacturer, or alternatively, can be performed by an end user. In one example, to reduce carton size during the shipping and retail phase, the blower handle 13 can be a separate part provided in the carton and intended for installation by the end user. The consumer could press the handle 13 into the engine housing 14 and secure it using any of the methods mentioned above, including by way of a fastener or the like. Likewise, if the handle 13 is designed to be attached in one of the other locations as described above, the consumer could affix the handle in the predetermined location.
In addition or alternatively, the blower 100 can be configured with a compact design to reduce the carton size during transport and/or retail sales. The total length and/or height of the blower 100 can be reduced such that the unassembled blower 100 will fit more readily inside of a relatively smaller sized carton. In one example, the total length (X) of the blower 100 can be divided approximately in half, though various other ratios are also contemplated. For example, the length (X2) of the blower tube 20 can be approximately equal to the overall length (X1) of the scroll housing 110, though the elements can be permitted to overlap to some extent so as to provide an acceptable connection and/or sealing arrangement therebetween. The blower tube 20 can be coupled to the scroll housing 110 in various removable manners, including fasteners (e.g., screws, bolts, etc.), snap/click fastening arrangements, press fit, interference fits, adhesives, and/or various other removable fastening arrangements. Thus, the length of the carton size can be relatively reduced by approximately half, and the blower tube 20 can be assembled to the scroll housing 110 by the end user before use. Of course, the blower tube 20 can also be subsequently removed from the scroll housing 110 to provide for a more compact storage arrangement.
In addition or alternatively, as described herein, the handle 13 can be provided in the carton as a separated component from the blower 100. When the blower 100 is shipped with the handle 13 detached, the height of the carton size can be relatively reduced by the extent to which the handle extends thereabove (e.g., above the uppermost portion, such as the power drive unit). As illustrated, the height of the blower 100 with the handle attached is Y. If the handle is removed, the height is reduced to Y1.
An exemplary top perspective view of the scroll housing 110 is illustrated in
A bottom view of the scroll housing 110 is illustrated in
The above described scroll housing 110 can be provided as a single or multiple piece shell. For example, the scroll housing can be provided as a single, unitary shell by various manufacturing processes, such as injection molding, blow molding, rotational molding, etc. In another example, the scroll housing 110 can be provided as a multiple piece shell, such as a two piece scroll as shown in
In one example, as shown more fully in
The projection 17 and the pocket 18 are more clearly illustrated in
A close up of a mated pocket 18 and projection 17 is illustrated in
The vibration/friction welding can be performed at various times in the manufacturing process. In one example, the vibration/friction welding can be performed relatively early in the manufacturing process when the upper scroll 11 and the lower scroll 10 are still warm/semi-hot and/or soft from their respective molding operations (e.g., at a relatively short time after forming each half). Thus, when the relatively warm/soft upper scroll 11 and the lower scroll 10 are placed into the fixed vibration/friction welding mold, the upper scroll 11 and the lower scroll 10 are welded together in a relatively accurate environment (e.g., provided by the fixed mold geometry) that can inhibit or prevent warping, defects, or the like that can otherwise compromise the seal between the upper scroll 11 and the lower scroll 10. As such, the fixed vibration/friction welding mold can help maintain tolerances of the scroll housing 110.
It can be beneficial to weld the upper scroll 11 and the lower scroll 10, as opposed to coupling via fasteners or adhesives, because a relatively higher quality, lower weight, and increased performance scroll housing can be achieved. In one example, the weight, parts, and labor associated with the fasteners or adhesive can be reduced or eliminated. Further, labor costs can be saved because less time is wasted trying to assemble warped parts. In another example, quality can be improved as the vibrational welding technique can reduce or avoid warping and/or provide fewer defects. Moreover, a weld joint 15, running along the entire perimeter, can be the strongest portion of the scroll to provide increased structural integrity. In another example, a substantially complete seal is provided between the upper scroll 11 and the lower scroll 10 by welding which establishes a hermetic seal that inhibits air leakage from the scroll housing 110 around the scroll perimeter during use of the blower 100. As such, fewer or even no additional seals are required between the upper scroll 11 and the lower scroll 10. Still, it is to be appreciated that one or more additional seals may be used between the upper scroll 11 and the lower scroll 10. Moreover, the welding can improve necessary tolerances to maintain a secure connection between the scroll outlet and the tube.
Other variations of the shape of the pocket and protrusion, as discussed above, are contemplated in embodiments of the present disclosure for joining surfaces of the first and second scroll halves. The scroll housing halves may be shaped in a manner such that the surface of the perimeter of one scroll housing half is the mirror image of the surface of the perimeter of the other scroll housing half. For example, a first scroll housing half may have one or more protrusions, forming a non-planar surface such as a flange, protruding from the first scroll housing half. A second scroll housing half may have on its perimeter one or more channels to mate with the protrusions of the first scroll housing half and thereby forming a mirror image of the one or more protrusions of the first scroll housing half such that the perimeters of the two scroll housing halves are flush against each other when joined. When fused or welded together, the joint described in this embodiment forms a continuous bond achieving even greater relative quality and performance due to increased rigidity, a stronger bond and a more efficient hermetic seal.
When assembling a blower according to the above disclosure, the engine and housing 14 can be installed once the scroll housing 110 has been welded together. With the engine or motor installed, the impeller can now be installed. Because the scroll housing halves have been previously coupled, an inlet opening 19, as shown in
While the above has been described in relation to an upper scroll housing and lower scroll housing, these portions can also be referred to a first and a second scroll housing. Additionally, the geometry of the joint 15 of the upper scroll housing 11 and lower scroll housing 10 can be reversed such that the geometry described above in relation to the upper scroll housing 11 could be positioned on the lower scroll housing 10 and vice versa such that the mating profiles are still present.
While described generally herein with reference to a handheld blower or blower/vac, it is to be appreciated that various other types of blowers can also be used, including back-pack style blowers, wheeled blowers, and the like. The blower has been described with reference to the example embodiments described above. Modifications and alterations will occur to others upon a reading and understanding of this specification. Example embodiments incorporating one or more aspects of the disclosure are intended to include all such modifications and alterations.
Claims
1.-17. (canceled)
18. A method of manufacturing a housing for a blowing apparatus, comprising:
- providing a first scroll having a perimeter therearound with a pocket formed therein;
- providing a second scroll having a perimeter therearound with a projection formed therein;
- coupling the first scroll and the second scroll together by forming a joint in which the projection of the second scroll fits within the pocket of the first scroll and then the joint is welded together.
19. The method of claim 18, wherein said joint is continuous such that air does not flow through said joint.
20. The method of claim 18, wherein said joint forms a ridged connection between the first scroll and the second scroll.
21. The method of claim 1, wherein said welding is friction welding.
22. The method of claim 1, wherein said welding is vibration welding.
23. The method of claim 1, further comprising providing an opening through which installation of an impeller is accommodated into the welded together first scroll and second scroll.
24. The method of claim 23, further comprising inserting an impeller through said opening into the welded together first scroll and second scroll.
25. The method of claim 24, further comprising covering said opening with an inlet cover fixedly attached to said second scroll.
26. A blowing apparatus, comprising:
- a scroll housing comprising:
- a first scroll half having a first perimeter, the first perimeter having a channel formed thereupon;
- a second scroll half having a second perimeter, the second perimeter having a protrusion extending therefrom, said protrusion of the second scroll perimeter being inserted into and mated with the channel of the first perimeter and the first scroll half and second scroll half being welded together along the mated perimeters of the halves and thereby forming a secured joint therebetween and thereby establishing the scroll housing.
27. The blower apparatus of claim 26, wherein said welding is friction welding.
28. The blower apparatus of claim 26, wherein said welding is vibration welding.
29. The blower apparatus of any one of claims 26, wherein said joint is continuous such that air does not flow through said joint.
30. The blower apparatus of any one of claims 26, wherein said joint forms a ridged connection between the first scroll half and the second scroll half.
31. The blowing apparatus of any one of claims 26, further comprising an impeller, wherein the impeller is positioned within the welded scroll housing.
32. The blowing apparatus of any one of claims 26, further comprising an inlet formed in at least one of said first scroll half and said second scroll half.
33. The blowing apparatus of claim 32, further comprising an inlet cover attached to the one of the first scroll half and second scroll half comprising the inlet.
34. The blowing apparatus of claim 33, further comprising an engine housing secured to the other of the first scroll half and the second scroll half opposite the scroll half comprising the inlet.
Type: Application
Filed: Dec 11, 2008
Publication Date: Oct 21, 2010
Applicant: HUSQVARNA CONSUMER OUTDOOR PRODUCTS N.A., INC. (Augusta, GA)
Inventors: John Allen (Texarkana, TX), Bob Samuelson (Nashville, AR), Andrew Curtis (Texarkana, TX)
Application Number: 12/747,610
International Classification: F04D 29/54 (20060101); B23P 17/04 (20060101);